Exploratory project at ÖBB-Holding AG
An exploratory project was held at ÖBB-Holding AG from 15.03.2019 to 31.05.2019 to sound out the technical feasibility of a pilot project for the use of hydrogen trains and hydrogen infrastructure on a suitable ÖBB-Infrastruktur AG line. The focus was on the technical feasibility, the economic and ecological evaluation and the assessment of the required hydrogen infrastructure.
Project Principal: A. Matthä (CEO ÖBB), M. Topal (CTO ÖBB)
Project Manager B. Ludwig (ÖBB-Holding AG)
Implementation project ÖBB Holding AG & ÖBB Personenverkehr AG
An implementation project - led by ÖBB-Personenverkehr AG and ÖBB-Holding AG - was set up in spring 2019 based on the exploratory project. The project structure is shown in Figure 1 below.
Project Principal: M. Huber, K. Garstenauer (Vst. ÖBB-Personenverkehr AG), M.
Topal (CTO ÖBB-Holding AG)
Project Manager M. Prießnitz (ÖBB-Personenverkehr AG), B. Ludwig (ÖBB-Holding AG)
Time Schedule Implementation Project
Originally, the trial operation was scheduled to take place between April and July 2020. A postponement became necessary due to developments related to the COVID-19 pandemic, which was also accompanied by a reduction in the number of vehicles from two to one hydrogen train. Passenger services ultimately took place from 12.09 to 26.11.2020, with the time schedule detailed in Figure 2.
Project structure
Final report Pioneer Project H2 Aspang railway 7/31 Project time schedule
Project partner:
The following project partners contributed significantly to the success of the project:
Alstom Transport Deutschland GmbH: Provision of the Alstom Coradia iLint train, hydrogen fuelling station as well as hydrogen supply
Climate and Energy Fund: Promotion of the project
Austrian Institute of Technology GmbH: Preparation of a study on hydrogen production for conversion of the Vienna Neustadt facility to hydrogen trains
HyCentA GmbH: Preparation of a study on hydrogen production for conversion of the Vienna Neustadt facility to hydrogen trains
VERBUND Energy4Business GmbH: Green certification of the hydrogen consumed in the project
Shift2Rail Joint Undertaking: Support of the Project
Final report Pioneer Project H2 Aspang railway 8/31
AP1 Hydrogen fuelling station
AP 1 Setting objectives & contents
The fuelling station work package comprised all work steps to ensure the commissioning of the hydrogen fuelling station at the start of operation. This work package therefore included, in particular, securing the approval for the construction of the fuelling station, as well as all infrastructural measures necessary for the operation of the fuelling station. The work package therefore comprised the production of all infrastructural necessities for the operation and installation of the hydrogen fuelling station, primarily the following steps:
Provision of a suitable, paved, fenced (approx. 10m x 10m) plot of land
Provision of electricity & power supply (3-phase 400V, 50 Hz.125 A for operation of the refuelling station; 3-phase 400V, 50 Hz, 63A for winter refuelling with outside temperature <0 degrees, 3-phase 400V, 50 Hz, 32 A for the train during refuelling).
Crane installation for setting up and dismantling the fuelling station
All measures required for the approval
Involvement of the stakeholders affected in the local area
AP1 Results
A temporary, mobile hydrogen fuelling station from the manufacturer Alstom was used during the trial operation. This essentially consisted of a high-pressure pump to bring the liquid hydrogen up to tank pressure, an evaporator and a dispenser for vehicle refuelling. The hydrogen was supplied in cryogenic form via a truck-mounted liquid hydrogen trailer, which also served as a storage tank. The hydrogen fuelling station had already been successfully operated at various sites in Germany before the project in Vienna Neustadt. The construction of the fuelling station in Vienna Neustadt was on property owned by ÖBB, which is why the permit was also covered by the Austrian Railway Act. The temporary construction of the petrol station was thus subject to a declaration in accordance with §40 Railway Act (EisbG) and was therefore exempt from approval. An expert opinion from TÜV Süd was also commissioned for the part relating to gas pressure for the §40 declaration.
As safety measures, electrical equipment in the immediate vicinity of the fuelling station was dismantled or deactivated, and the installation area of the fuelling station was paved (concreted) with gas- and liquid-proof, non-combustible material. Furthermore, a barrier (fence) and a crash barrier were erected. Shafts leading into the subsoil were installed as
"cable shaft covers made of GG class D 400kN". In addition, the construction of the petrol station took into account any installations (e.g. gas lines, power lines) as well as sufficient distance to other buildings. A corresponding alarm and operation plan was drawn up for the fuelling station, which includes a detailed sketch of the location as well as special hazard
Construction of fuelling station Hydrogen trailer & compressors
Final report Pioneer Project H2 Aspang railway 9/31 warnings (such as the danger of cold burns caused by cyrogenic liquid hydrogen). The alarm and operation plan was provided to the fire brigade accordingly and also deposited locally at the petrol station as well as in a plan box at the fire brigade service station of the site. The blue-light organisations and the municipal authorities of the city of Vienna Neustadt were informed about the project at an early stage, and an inspection by representatives of the local fire brigade also took place during the commissioning.
The hydrogen used was provided by Air Products - in liquid hydrogen trailers filled with liquid hydrogen. These were vacuum-insulated tanks, which are subject to dangerous goods legislation. Liquid hydrogen was drawn from the tank during the refuelling process. This was then compressed to 450 bar via a pump, subsequently evaporated via heat exchangers and temporarily stored in a high-pressure cylinder bundle. The gas pressure tanks in the vehicle (fuel gas tanks) are fed from the high-pressure cylinder bundle via the dispenser. Overfilling of the fuel tanks in the train is prevented by a data interface between the train and the fuelling station as well as safety devices in the vehicle.
AP1 Conclusions
Simple approval of the fuelling station by §40 - Persons pursuant to Railway Act (EisbG), as located on railway property.
Early involvement of blue-light organisations and local stakeholders is beneficial.
Hydrogen trailer & compressors Compressor
Final report Pioneer Project H2 Aspang railway 10/31
AP2 Hydrogen supply
AP2 Setting objectives & contents
The hydrogen supply work package comprised all work packages that ensured a supply of hydrogen for the start of operations. It should be noted that the necessary tender procedure for the hydrogen supply was undertaken in conjunction with the vehicle tender procedure (AP 4.1.). Another priority of the hydrogen supply work package was the green certification of the hydrogen consumed, as the supply of green hydrogen could not be guaranteed in this project due to the lack of availability of green, cryogenic hydrogen in Europe.
AP2 Results
Finally, the rental of the vehicle was accompanied by the hydrogen supply; the hydrogen required was provided by Alstom via Air Products. The green certification of the required hydrogen was performed by VERBUND Energy4Business GmbH.
AP2 Conclusions
Strongly limited availability of green liquid hydrogen in Europe.
Green certification of hydrogen possible together with partner.
Delivery of hydrogen by rail currently not possible.
A supply of liquid hydrogen is most likely out of the question for scheduled operations due to availability and energy efficiency.
AP3 Maintenance
AP3 Setting objectives & contents
The maintenance work package includes all work packages that ensure that maintenance is possible on hydrogen trains. The maintenance itself was provided by the vehicle manufacturer Alstom (ECM I, II, III and IV function), while ÖBB-Technische Services provided personnel support for maintenance as required.
The provision of the infrastructural framework conditions for the maintenance of the hydrogen train and the provision of the required areas was an essential goal of the work package. Among others, the following infrastructural measures were requested:
Adaptation of the workshop incl. provision of areas for maintenance work (2 x roof work stand 6m, crane (2 tonnes for fuel cell work), crane 100kg for general roof work as well as adaptation of the work pit).
Provision of a hoist
Provision of spare parts storage (storage container, 40 feet, frost-protected)
Provision of office workstations for employees of the vehicle manufacturer
Provision of operational materials
Provision of connections (3-phase 400V, 50 Hz, 32 A)
AP3 Results
The workshop was adapted for the maintenance of the vehicle corresponding to the above specifications of the vehicle manufacturer and the areas necessary for maintenance were provided.
The scheduled maintenance steps (light maintenance) could be completed through structural upgrades and provisioning in the workshop. The need for a truck-mounted crane to replace fuel cell components was known in advance - accordingly, the necessary steps were evaluated at an early stage. Complications and delays could as a result be avoided.
Final report Pioneer Project H2 Aspang railway 11/31 The installation of hydrogen-specific safety equipment such as explosion-proof lighting and heating, hydrogen sensors incl. alarm system and ventilation system in the hall was dispensed of due to the time limitation of the trial operation. As a consequence, no work was possible on the hydrogen components in the hall (this was done outside in the case of unscheduled demand).
AP3 Conclusions
Concepts are required that enable employees to work safely on and around hydrogen-powered vehicles.
Evaluations are required as to whether or under what conditions hydrogen-powered vehicles and e-powered vehicles (especially vehicles that are supplied with energy via the overhead line) are able to be serviced in the same facilities.
A modular design of the components conveying hydrogen promotes ease of maintenance.
AP4 Provision of vehicles
AP4 Setting objectives & contents
The vehicle provision work package comprised the tender procedure for the implementation of the trial operation with an approved hydrogen train incl. maintenance, fuelling station and hydrogen supply. This was also associated with the network approval of the hydrogen train by ÖBB-Infrastruktur AG and the granting of the vehicle approval in Austria by the Federal Ministry for Climate Protection, Environment, Energy, Mobility, Innovation and Technology (BMK). The content of the work package is presented in detail below:
Tendering procedure for the rental of a hydrogen train approved in Austria incl.
maintenance, refuelling station, hydrogen supply
Tendering procedure for the lease of a hydrogen train approved in Austria incl.
maintenance, refuelling station, hydrogen supply
All steps for a network approval of the hydrogen train by ÖBB-Infrastruktur AG and the vehicle approval in Austria by the Federal Ministry of Transport, Building and Urban Affairs (BMK).
Transfer and return of the vehicle to/from Vienna Neustadt
Conclusion of liability insurance
It was contractually agreed in advance that the manufacturer would be responsible for obtaining approval for the hydrogen train on the Austrian route network. On 28.10.2020, the BMK finally issued the type approval and operating permit in accordance with § 32a of the Railway Act (EisbG) as amended.
The approval of ÖBB-Infrastruktur AG for the use of the hydrogen train on the rail network of ÖBB-Infrastruktur AG was granted on 28 February 2020
The following measures, among others, were necessary to obtain access to the network:
Test runs with tight curve radii: The hydrogen train was transferred to Austria in December 2019 in order to obtain this evidence. The measurement runs to verify the wheel-rail forces were performed over two days:
o Test runs at the Breitenstein infra-measuring station
o Measurement and test runs at Söchauer Berg (min. arc radius 120m). This measurement run also checked the turning angle of the running gears and the load on the air springs.
Final report Pioneer Project H2 Aspang railway 12/31 The measurement runs were accompanied by experts from ÖBB-Infrastruktur. The hydrogen train was also presented to several stakeholders (blue-light organisations, traffic operations inspectorate and VOR) as part of these measurement runs.
AP4 Results
The following results were achieved in the work package:
Framework agreement / rental agreement incl. two supplementary agreements for the trial operation of a hydrogen train
Successfully completed test & measurement runs
Documentation of the measurements (test reports)
Network approval for hydrogen trains on the Austrian railway network
Vehicle Licensing in Austria for hydrogen train
AP4 Conclusions
Network access route network ÖBB-Infrastruktur AG was achieved to the highest satisfaction of all project participants.
Project team (not complete)
Final report Pioneer Project H2 Aspang railway 13/31
AP5 Operational implementation
AP5 Setting objectives & contents
The Operational Implementation work package comprised all components necessary for the vehicle to be able to run in regular passenger transport operations and be ready for use. The following steps were necessary in this regard:
Train driver - training: A sufficient number of train drivers needed to be trained before the start of the vehicle operation. All documentation required for this (service aids, operational guidelines) needed to be prepared in advance. The transfer of the training content was ensured by a total of four train driver instructors, who had already received vehicle familiarisation training in advance.
On-board train attendant - training: A sufficient number of on-board train attendants needed to be trained before the start of the vehicle operation. All documentation required for this (service aids, operational guidelines) needed to be prepared and the training courses provided. The provision of training was ensured by an on-board attendant instructor who had already received vehicle training in advance.
Cleaning and security: Here, too, the employees of the cleaning and security company were trained in the necessary vehicle specifics.
Ensuring system integration: The vehicle was integrated into the necessary system landscape in order to ensure both scheduling and the maintenance management (ECM III function).
Evaluation of operational safety relevance (risk analysis/RIA) safety management/SMS, route evaluations): All operational safety-relevant evaluations for the operation of the hydrogen train were performed here. The risk assessment was based on the manufacturer's comprehensive risk analysis. In addition, a safety assessment regarding accident risks of hydrogen-powered vehicles was ordered from the TÜV-Süd testing facility.
Schedule and deployment planning: A comprehensive evaluation of the schedules for the hydrogen train was undertaken in order to ensure timely refuelling of the vehicle in any case, but also to ensure an extensive test of the vehicle. The vehicle schedules were chosen in such a way that the train could be parked overnight in the service facilities in Vienna Neustadt in order to avoid damage caused by vandalism.
Worker protection: An inspection of the vehicle by representatives of the Transport Work Inspectorate (VAI), preventive physicians and ÖBB safety experts had already taken place in December 2019 to ensure occupational health and safety. Prior to the immediate start of operations, a second inspection including the preparation of the required SIGE document took place.
Blue-light organisations: Two inspections were conducted with representatives of the local fire brigade to ensure that the emergency services along the route are informed about the use of the hydrogen train, especially with regard to preparation for emergencies or unforeseen events. An updated operational fact sheet was prepared in cooperation with them.
Final report Pioneer Project H2 Aspang railway 14/31
Positioning and parking concept: Suitable parking areas for the hydrogen train were to be assured, preferably in the vehicle hall, to prevent vandalism (especially graffiti).
In addition, security was arranged by the company Mungos for the parking hours during the night.
Auxiliary train: Immediately after the transfer of the vehicle in August 2020, the training of the auxiliary train staff also took place.
Passenger Information System (FIS): All necessary FIS data for integration into the vehicle FIS were recorded by PV-D in order to display correct information (timetable etc.) in the vehicle.
AP5 Results
The following results were achieved in the work package:
(Operational) readiness of the vehicle for use
Project / use of hydrogen train coordinated and agreed with the contractor
Sufficient number of trained drivers available
Documentation for train drivers (DB, guidelines) available
Sufficient number of trained attendants available
Hydrogen train incorporated into the necessary IT systems
Risk analysis (RIA) undertaken and completed
Vehicles "incorporated" in SMS
Route evaluation with hydrogen train successfully completed
Schedules planned for hydrogen train and coordinated and agreed with manufacturer
ANS and SIGE evaluation available
AP5 Conclusions
High level of cooperation within ÖBB, with blue-light organisations, purchasers and vehicle providers during operational implementation.
The high level of support from all the agencies involved also resulted from the high level of interest in the innovative vehicle and tank installation technology.
Final report Pioneer Project H2 Aspang railway 15/31
AP6 Operation & lessons learned
Setting objectives & contents
The Operation & Lessons Learned work package ensured that the hydrogen train could be used in passenger service. The findings were documented, evaluated and conclusions drawn on an ongoing basis. The clear objective here was to derive conclusions and recommendations for action on how a possible future use of hydrogen trains on the Austrian route network could be achieved. Operational, economic and technical aspects were all taken into consideration.
AP6 Vehicle deployment
The vehicle transfer from Salzgitter/Germany to Vienna Neustadt was performed by the RCA on 19.08.2020. Immediately afterwards, the process of operational implementation of the vehicle began: Vehicle inspections by the Austrian Railway Authority (VAI) and blue-light organisations took place in addition to the training of drivers, on-board attendants and technicians. Passenger service commenced after the official opening event at Vienna Central Station on 11.09.2020. The operation was completed as scheduled on 26.11.2020.
Planned operating days Actual operating days Actual kilometres
76 50 Ca. 14,700 Km
AP6 Vehicle breakdowns and punctuality data
A total of 19 standstill days were recorded during the entire trial operation due to vehicle downtime. One standing day due to scheduled maintenance on 16.11.2020, as well as the standing days after an EC accident on 19.11.2020, are not taken into account here. The majority of the downtime was due to technical defects of the prototype as well as the long delivery time of the replacement components required for repair (complicated by the COVID 19 pandemic). In regular operation, the vehicle showed no significant deviations from the scheduled timetable
AP6 Experiences of train drivers
The training of the train drivers took place from 19.08.2020 to 10.09.2020 over a period of 16 hours (theory), the practical part of which was completed during the evaluation runs of the four test routes. A total of 20 train drivers were instructed by 4 instructors who had already been familiarised with the specifications of the vehicle in advance.
The drivers were of the opinion that current timetable with the hydrogen train could be maintained without difficulty.
Final report Pioneer Project H2 Aspang railway 16/31 It was emphasised that the hydrogen train represents an interesting technological development in terms of smoothness, curvature and, above all, noise development. The refuelling process with the prototype fuelling station is currently judged to be too cumbersome and lengthy for real operation - a fixed fuelling facility with larger tanks (or a higher range of the vehicle in order to have to refuel less frequently) is desirable.
AP6 Digression: Legal considerations for the production and supply of hydrogen on railways
Mag. Andreas Netzer (ÖBB-Infrastruktur AG) was asked by the project team to provide an outlook on the potential production and supply of hydrogen in the future. The relevant considerations are set out in the following.
Are installations for supplying railway vehicles with energy for propulsion
Are installations for supplying railway vehicles with energy for propulsion